Indicating apparatus



y 1948. R. c. FREEMAN ET AL 2,441,406

INDIGATING APPARATUS Filed June 27, 1944 2 Sheets-Sheet 1 Fig. I.

ARC WELDER REVERSE O L AR IT Y=O Inventors: Raymond Cfreeman,

Richard F Wyei,

by WW4. AMA;

Their Attorn ey.

May 11, 1948. R. c. FREEMAN ET AL INDICATING APPARATUS Filed June 27, 1944 2 Sheets-Sheet 2 Fig. 3.

EVERSE POLARIIY ARC WELDER START STOP 111i!)III/11 Illiilil7/IiklillI11)! Inventors: Raymond C. Freeman,

Them Attorney.

Richard F Wyer,

Patented May 11, 1948 INDICATING APPARATUS Raymond C. Freeman, Marblehead, Mass., and Richard F. Wyer, Rexford, N. Y., assignors to General Electric Company, a corporation of New York Application June 27, 1944, Serial No. 542,390

Claims.

Our invention relates to improved apparatus for presetting the current output of a generator whose characteristics are dependent upon the combined adjustment of a. plurality of control elements which are independently movable and mutually effective in determining the operating characteristics of the generator.

In accordance with our invention a generator controller is provided with scale and pointer means which is operated by the independent adjustments of a plurality of elements of the controller to indicate to the operator the selection of one of a plurality of generator current output ranges determined by an adjustment of one of the generator control elements and the selection of a particular generator current output value determined for any selected current output range by an adjustment of another of the generator control elements.

Generators having two independently adjusted and mutually efiective excitation controls are well known in the art and are frequently referred to as dual control generators. These generators may be employed as arc welding generators when they have operating characteristics which particularly suit them for supplying current to an are employed in forming welds on or between parts in accordance with a desired welding procedure. The wide range of current adjustments obtainable with such generators is highly desirable for the variety of arc welding conditions determined by the mutually dependent factors of work size, electrode size, welding current, heat and the like employed in performing each different welding operation.

In dual control arc welding generators this wide range of current adjustment may be obtained by controlling, electrically or magnetically, the eifective flux of the generators fields. For example, the output ranges of the generator may be determined by a series field adjustment and the current value in each output range thereafter determined by a shunt field adjustment. It is highly desirable to correlate these two adjustments by means of a suitable indicator so that the welding operator may preset the generator for the welding operation he is about to perform.

It is an object of our invention to provide a generator control in which the range of current values and the current value in a selected range are indicated by the operation of control handles used in making these adjustments.

It is a further object of our invention to provide a dual control generator with indicator means operated by movement of the handles of the generator controller to register on a single dial current output ranges in accordance with electrode size, or some other welding factor depending on current output range, and the selection of a preset current value in any current output range.

It is also an object of our invention to provide a dual control arc welding generator with an indicator having scales graduated in current values for electrode size and having pointer means for indicating on said scales the effect of the adjustments of the dual controls of the generator so that the welding operator by reference to the indicator may select current output ranges ''in accordance with electrode size and preset the current to be delivered in any range selected in accordance with electrode size.

Further objects of our invention will become apparent from a consideration of the following description of two embodiments of our invention illustrated in the accompanying drawings.

In these drawings, Fig. 1 is a front view of the indicator of a controller embodying our invention and Fig. 2 is a diagrammatic view illustrating the manner in which the elements of this indicator are connected in accordance with our invention with the control means of a dual control, direct current, arc welding generator of the splitpole self-excited type. Fig. 3 'is a front view of another form of indicator embodying our invention as applied to the control of an arc welding generator of the type illustrated in Fig. 2 and Fig. 4- is a sectional view of the rheostat and tap switch operating mechanism of a controller embodying our invention and having the indicator mechanism shown in Fig. 3.

In accordance-with our invention the current output of a dual control generator is selected by scale and pointer means which is responsive to the individual adjustments of the dual controls of the generator. If the dual control generator is an arc welding generator, the indicator scale is graduated in accordance with electrode size and current values for electrode size so that excited generator of the typeillustrated and" fully described in United States Letters Patent 1,340,004, Sven R. Bergman, May 11, 1920. This generator has an armature 2 provided with main brushes 3 and 4 through which arc welding current is supplied to the work 5 and an arc'welding" electrode 6 supported in arr-electrode holder 12::

For certain welding operations ittisxde'sirablv 3 to have the positive terminal 'of the generator connected to the work whereas for other welding operations it is desirable to have the positive:

terminal of the generator connected to the arc welding electrode. In the arrangement shown in Figs. 1 and 2 this selection of polarity is obtained through the agencyof a reversingiswitohza oper-' ated byqaacontrold iandle 9; Control handle 9, as

shown'in Figs; 1 and 2;.is in'the position for Straight. polarity, that is,. with the positive terminal of the generator connected tothe. work.

If this control handle is moved to the. positionidentified inFig. 1 as Reverse, switcha will be operated to complete a circuit from the positive terminal of generatorZ toelectrode Bin electrode holder 1.

Generator l is also provided with an auxiliary brush [0. One-terminal of the self-excitedshunt field H of generator I is :connected-tothis auxiliary brush l0 andthe other terminal-is connected through a fixed resistance l2, an'adiust able resistance lfi and the -commutating field- M of the generator to its'mainbrush 4.- Fixedresistance l2 isoptional and may beomitted if adjustable resistance l3 is'of-prOpervaIue. excitation furnishedbyshunt field H. is deter- The mined by the; adjustment-of variable resistance [3 obtained byrotatinga: control handle L5.

This. controlhandleds.conne'ctedby means of a shaft: 16 tothemova-blecontact arm ll of iustable resistance13;. A dial plate: l8- mounted-- on .andrhaving atdriving connection withishaft'. i6 -for:r.otation therewith is provided with five.

concentric scalesl 9- graduated. in. rangesof cur rent value for. electrodes. of :differentsizes.

Generator I. is also'provided-with axseries field;

28 selected: portions. .iofp which' arev connected in.

its output circuit:through .the. agency. of a tap switch 2|.

circuit for cumulative: excitation and. its other four sections in-.the1generator.outputlcircuit for differential excitation. turns and their differential or cumulative connections in the generators load. circuit determine;

The connections? completed through." tap switch 2! provide for placing the-left end section of series field. 20in the generator output The. number: at series current output ranges of the generator which are selected-byeach-of the=ilvepositions of tap switch 2|.

Thistap'switch 2| is movedxtoany one of its five positions through the agency of. an index handle 22 wh'ich issconnected by"a.-.shaft 23 to the blade of ta'plswitch 2|. The face plate 24 of the indicating mechanism is provided with:

five position' markers- 25 identified byran elec--" trode size or a range of electrode" sizes: .When

the hand grip portion- 01 controlrhandle 22',"

which; as shown in Fig. 1, is marked Electrode; is in any one of the positions 25, the pointer portion oithis handle, which I151 .marked Amperes, selects oneof-the-concentric: scales:

l9 of dial l8 having current value graduai'lozle corresponding to the range of current values obtainable by the movement of tap switch 2i resuiting from the positioning of control handle Once such an adjustment for current range has been made in accordance with electrode by movement of control handle 22 to the desposition, any current value in the range of current values thus established may then be cb- :tained by rotation of control handle it w adjusts the shunt field rheostat iii an controlsthe shunt field excitation of the crater. As handle this'ad-iustment, that scale It on l by the'pointerportion of handle relative thereto to indicate the pre. outputof thegenerator determined by the binedadjustments of the series and slnmt of theagenerator accomplished by operation the dual control handles !5 and 2 It will .be noted that each of the five current output ranges in Y accordance y trode size. is also identified by the olec or-therange of electrode size for which this range oi-current values is suitable. Consequently th position-markers 25 on face plate E l may b' omitted if desired since the information necessary for enabling the welding operator to presc the'cur rent output of generator 4 in accordance with electrode-size is contained on a sin l8-which isrotatable relative to the L tion of control handle 22 which is movable to five-difierent positions to select any one of the five current rangescales 59 on dial l8. It will also benoted, as indicated on the concentric scales l-S- of dial l8, that the dual control for generator l-is constructed and arranged to vide overlappingcurrentoutput ranges for diiferent sizes of electrodes. This is a oonvcni and desirable feature. It will also be noted ti as; control handlerz is rotated in a clock direction fromthe position illustrated past e :1 ofthe-electrode positions 25 on face plate i l the. pointer: portionofthis handle is positioned over scales [940i dial is in the following order: outer scaleimiddle soale. inner scale, scale between the inner andmiddle scale, and scale between middle scale and the-outer scale. It that the; order of selection may be 0 h dependingon the correlation of the a; p v of the indicator.

.In view of the 2abovedescription, the operation and use of the equipment illustrated in 1 andx2 is believed to be obvious. Briefly it is as follows:

The operator connects the welding generator 1 in the welding circuit in accordance with the polarity desired by operating control handle 5 which operates reversing switch 8 to obtain the desired connection. Thereafter in accordance with the electrode size to be employed in the welding operation, the operator moves control handle 22 to that position corresponding with the electrode size to be employed. Movement of this control handle to this position adjusts tap switch 2| so as to provide a current output range for-generator l which. is suitable for the electrode being used-in performing the welding operation.- Thereafter the operator by turning control' handle I5 brings the current setting on that scale 19 of dial [-8 which is covered by l6 pointer portion of handle 22 to the current value atrwhichit is desired tooperate the welding generator. Rotation of handle i5 controls the shunt fleld-texcitationofgenerator I- by adjusting selecting polarity the Welding operator can pre- 1 set the welding apparatus to operate at a desired current value which is within a range determined by the electrode size which he desires to employ in performing this welding operation. Not only is he informed as to the selected range of cur-- rent values to use with a particular electrode size, but he is enabled to accomplish a setting of the apparatus for a particular current within this range without the aid of the voltmeters and ammeters usually provided with such apparatus for enabling him to accomplish this result.

In Figs. 3 and 4 we have illustrated another embodiment of our invention which differs from that illustrated'in Figs. 1 and 2 by the different arrangement of physical parts employed for accomplishing the same purpose. As shown in Fig. 3 the arrangement of the parts of the indicator is different from that illustrated in Fig. 1 and, as illustrated in Fig. 4, the assembly of the tap switch, shunt field rheostat and the operating mechanisms therefor, is different from that illustrated in Fig. 2 although forming part of the same or a like dual control.

In the indicator mechanism illustrated in Fig. 3 the current output range scales 26 are segmental in shape and form part of the face plate 21 of the dual control cabinet structure. Each segmental scale is graduated in current values and identified by the electrode size or range of electrode sizes to be used with said range of current values, It will be noted that each of these scales overlaps the other and has a current range overlapping that of an adjacent scale. Each of these scales is also provided with an index 28 to indicate to the operator that position in which the pointer portion 29 of an index handle 30 is to belocated in order to adjust a tap switch, such as 2| of the dual control illustrated in Fig. 2, for obtaining the desired output-range of current values from a generator, such as of Fig. 2. When the pointer portion 29 of control handle 3!! is opposite any one of the indexes 28 of scales 2B, the operator is informed that the tap switch has been operated to a position which will make available a current output range of the generator corresponding to that indicated by the graduations of that scale. A pointer knob 3| is provided for adjusting a shunt field rheostat, such as l3 of the dual control illustrated in Fig. 2, for securing any preset current value in the range of current output values determined by an adjustment of index handle 3|]. trated in Fig. 3, the controller has been set by an operation of control handle 30 for current output ranges of from 120 to 240 amperes which is suitable for electrode sizes of 's to I32; inch and a particular current value of 200 amperes has been selected in this range by the adjustment of pointer knob 3|,

As in the arrangements illustrated in Figs-1 and 2, a control handle 32 is provided for selecting the desired polarity for the welding operation. As in Figs. 1 and 2, this control handle 32 operates a reversing switch connected in the output circuit of the generator in the same manner as the reversing switch 8 of the system illustrated in Fig. 2.

The rheostat and tap switch operating mechanisms of the controller shown in Fig. 3 have been illustrated in Fig. 4. As shown in this figure, the index handle 30 is attached to one end of a hollow shaft 33 to which is also attached the blade Thus, as illus- 34 of a tap switch 35 having contacts 36. Tap

switch 35 is the same or an equivalent of tap' switch 2| shown in Fig 2. A rheostat 31 corresponding to rheostat l3 of Fig. 2 is mounted on the inner end of hollow shaft 33 of tap switch 35. This rheostat is provided with a contact arm 38 mounted on one end of a shaft 39 journaled in hollow shaft 33 which has pointer knob 3| attached to its outer end. Obviously contact arm' 38 of rheostat 31 corresponds to contact arm I! of rheostat 3 of Fig. 2. The assembly as a whole rigidity of this support.

By reason of the arrangement shown in Fig. 4 it is obvious that an adjustment of control handle 38 to adjust tap switch 35 will not only bring pointer portion 29 of this control handle opposite the index of scale 26 giving the range of output current values for this adjustment, but will also carry along shunt field rheostat 3'! and pointer knob 3| to this same scale. Thereafter an operation of pointer knob 3| by reason of its driving connection with shaft 39 will enable the operator to select the desired current value in this scale by adjusting contact arm 38 of shunt field rheostat 31. Consequently there is no opportunity afforded the operator for setting ointer knob 3| with regard to a scale not selected by the operation of control handle 39 to determine a desired range of current operating values.

By reason of the description given above, the operation and use of the apparatus illustrated in Figs. 3 and 4 is obvious.

From the above description of two embodiments of our invention, other embodiments thereof will occur to those skilled in the art. Thus for example in Fig. 1, dial |8 may be fixed relative to or form a part of face plate 24 and control handle l5 may be provided with a pointer which can be positioned relative to any of the scales l9 of this dial |8 which has been selected by an opera-v tion of control handle 22. Another arrangement may be obtained by mounting a dial plate, such as 8 of Fig. 1, for rotation with a hollow tap switch shaft, and a pointer knob mounted on the rheostat shaft which is journaled for rotation'in the tap switch shaft as in Fig. 4 may be employed for selecting current values in any one of the range scales provided by an operation of the tap switch handle. It is of course not necessary to mount the rheostat on the hollow tap switch shaft as in Fig. 4 since an independent mounting may be provided therefor. In such case the pointer portion of the tap switch handle will be provided with a scale indicating electrode size or range of electrode sizes for each of its positions, and a corresponding electrode size identification will be associated with each of the concentric scales of the dial.

Obviously in any modifications of our invention the indicator scales for different current output ranges may be distinctively colored to facilitate identification and use thereof. Furthermore, in an arrangement such as illustrated in Fig. 1 the position markers 25 identified by electrode size Additional bearings, not shown, may also be provided for adding to the controhdirectcurrentgenerators than that illustratediand described above may :berused without departing vfromour invention. Also, as stated above, 'the current adjustments .of such generators'neednot 'be-obtainedby a tap switch and rheost-at as described in connection with the two embodiments illustrated since a pluralityof tap switches -a plurality of rheostats, a pluralityof controls foriadjusting the reluctancesof the magnetic -.circuits .of the :gei1EIa,t01', a plurality of adjustablepotentiometer circuits or aiplurality -of adjustable shunts which may be'either inductive or :non-in'ductive, or any combination of these elements maybe-used: for electrically or magneticallyrcontrolling the effective field flux of a dual control generator depending ofcourse on the type of generator employed.

-Furthermore the'several ranges of arc welding current values determined-by an adjustment of the dual control apparatus may be based on some other factor than electrodesize and consequently these-ranges may be identified by welding terminology which'has like significance with respect to the limitations of each of the current ranges such as type of work and heat values. Thus instead of identifying positions of adjustment-of one of the-control handles of the'dual control'by electrode size, these positions may be identified in accordance with various degrees of Heat such as High, Medium, and Low or as Work with suitable dimensions or ranges of dimensions associated therewith for-each range of current values used in welding work of that dimension or range of dimensions.

These and other variations-will readily occur to those skilled in the art. Thus, while 'wehave shown-and described but two embodiments of ourinvention, itis apparent that other embodiments-thereof will occur to those skilled in the art-and we therefore intend to cover by the appended claims all such modi'fications of our invention as fall within the true spirit and scope thereof.

What we claim as new and desire to secure by Letters Patent of the United States is:

,1..Arc weldingnapparatus comprising a-source of :arc welding current, an adjustable control means for determining a plurality of overlapping currentoutput ranges for said source of arc Welding-current, a second adjustable control means fordetermining the current value of said source of arc welding current for each of thecurrent output ranges determined by said first'control means, alplurality of scales each of which is identified .by an arc welding electrode size and each of which is graduatedlincurrent values .for .one of said overlapping current output ranges determined by said first. mentionedadjustable control meanswin accordance with said electrode size, a pointer associated with said scales, and means for moving each-of said adjustable control means invidually and correspondingly moving said scales and pointer relatively to one another in response to the individualradj ustments ofeachof said control means. for selectingrsaid arc welding current output ranges in accordance with electrode size and for adjusting the current value ina current output range selected in accordance with electrode size.

'2. Are welding apparatus comprising a source of .arc Welding current, an adjustable control means fordetermining arplurality of current output ranges for said source of arc welding current, a second adjustable control means for determininlthe current value of said source .ofarc welding current for the current range determinedby said first control means, an index handle movable to a plurality of positions identified by electrode size, means responsive to the movement .01 said index handle to each of said positions identified by electrode size for adjusting said first mentioned control means for current output ranges of said source of arc welding current corresponding to the electrode sizes indicated at said positions, a plurality of scales each of which is selected by said index handle in accordance with the position to which said handle is moved to determine current output range for electrode size, and means-having a driving connection with said second mentioned adjustable control means for'mcving said scales relatively to said index handle in response tothe adjustment of said secondmentioned control means to indicate the current value for which said source of arc welding current has been adjusted by operation of both of said control means.

3. Are welding apparatus comprising a source of arc Welding current, control means for deter mining in accordance with electrode size a plurality of current output ranges for saidzsource of arc welding current, means includingan index handle for adjusting said control means for output ranges of said source of arc welding current determined by the position of said handle, means for marking the positions of said handle in accordance with electrode size corresponding to the-current output ranges of said source of arc welding current, a plurality of scales each of which is selected by said index handle in one of its said positions, said scales being graduatedrin current values corresponding to the current range determined by the position of said index "handle, a second control means for adjusting the current value of said source of arc welding current'within the range determined by an adjustment of said first mentioned control means, means for'adjusting said second control means, and a pointer movable over any one of said scales selected by said index lever and operated by movement "of said adjusting means for said second control means to indicate on one of said scales selected by movement of said index handle to one ot its said positions the current value for which said source of arc welding current has been adjusted by operation of both of'said control means.

4. Apparatus comprising a source of current. control means for determining a plurality of current output ranges for said source of current. means including a rotatably supported tubular shaft and a handle mounted thereon for adjusting said control means for output ranges'of said source of current determined by the position of said handle, a plurality of scales each of which is selected by a pointer operated by movement of said handle to one of its said positions, said scales being graduated in current values corresponding to the current range determined by the position of said-handle, a second control means foradjustingthe current value of said source of current within the range determined by an adjustment of said first mentioned control means, means for supporting said second control means on said tubular shaft for rotation therewith, means including a second rotatably supported shaft extending through said tubular shaft and having an operating handle adjacent said first.mentioned handle for adjusting said second control means, and a second pointer movable overany one of saidscales selected by said first mentioned, pointer and operated by rotation imparted to said second shaft by its said operating handle for indicating the current value for which said source of current has been adjusted by operation of said handles of said control means,

5. Arc welding apparatus comprising a source of arc welding current, control means for determining in accordance with electrode size a plurality of current output ranges for said source of arc welding current, means including a rotatably supported tubular shaft and a handle mounted thereon for adjusting said control means for output ranges of said source of arc welding current determined by the position of said handle, a plurality of scales each of which is for electrode sizes corresponding to one of said current output ranges of said source of arc welding current and each of which is selected by a ointer operated REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,720,446 Sarazin July 9, 1929 2,000,161 Burgett May 7, 1935 2,279,157 Blakenbuehler Apr. 7, 1942 

